SEW-EURODRIVE has supplied 150 MOVIGEAR® mechatronic drive units to a leading automotive manufacturer in Gauteng, enhancing conveyor efficiency, safety and energy savings in a newly expanded buffering zone. The integrated, decentralised system reduces maintenance, simplifies stockholding, and enables real-time condition monitoring for predictive maintenance.
A major automotive manufacturer in Gauteng has boosted its operational efficiency, safety and energy savings with the installation of SEW-EURODRIVE’s advanced MOVIGEAR® mechatronic drive system in its newly expanded buffering zone.
The project delivered 150 MOVIGEAR® units to drive conveyors in a high-density storage area. According to Willem Strydom, Electronics Business Development Manager at SEW-EURODRIVE, the customer’s goal was to standardise equipment to simplify stockholding and maintenance, while meeting strict safety and performance requirements. These goals were met using just two MOVIGEAR variants, avoiding the need for up to 30 conventional motor variants and significantly reducing inventory complexity.
Each MOVIGEAR unit integrates a servomotor, gearbox and electronics, offering decentralised functionality with onboard communication and safety features. The system eliminates the need for traditional control panels with all units linked to a compact PLC via hybrid cabling in a daisy-chain configuration. This accelerates installation and lowers infrastructure costs.
SEW-EURODRIVE worked closely with the original equipment manufacturer responsible for the conveyor installation, providing design input and on-site support during installation and commissioning. The reliability of the MOVIGEAR units has already been proven across multiple industries, including food and beverage, and the units at this site have been running reliably since commissioning in January 2025.
A second phase of the project introduced condition monitoring using MOVIGEAR’s digital data interface, enabling real-time tracking of performance variables such as vibration and temperature. This data is used to predict maintenance requirements, creating a digital twin of each unit to help prevent unexpected failures and extend equipment life.
With ultra-premium-efficiency IE5 SEW electric motors, the MOVIGEAR system also delivers substantial energy savings of over 38% compared to conventional motors, while offering IP69K protection for demanding environments.
By engaging from the project’s early stages through to final optimisation, SEW-EURODRIVE delivered a fully integrated and future-ready solution that supports the manufacturer’s productivity, safety and sustainability objectives.
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